Lecture 01 2010

LECTURE 1

INTRODUCTION TO MANUFACTURING

MANUFACTURING PROCESS

(BMCU 1323)

Prepared:Masjuri bin musa @ othman

LecturerDepartment of design & innovationFaculty ofmechanical engineering

Universiti teknikal malaysia melaka

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DEFINITION OF MANUFACTURINGWhat is “MANUFACTURING”?

“the process of converting raw materials into products”.

The word “manufacturing” is derived from the Latin manu factus, meaning made by hand.“the conversion of stuff into things” – (by DeGarmon, 1998).

“processing or making a product from raw materials, especially as a large scale operation using machinery” – (by Collin English Dictionary, 1998).

“economic term for making goods and services available to satisfy customer” - (by T.Black, 1991).

@jurie 2009 – Lecture 1

INTRODUCTION TO MANUFACTURING

2/26INTRODUCTION TO MANUFACTURING

IN MODERN CONTEXT, MANUFACTURING CAN BE DEFINED AS:

- “the making of products from raw materials using various processes, equipments, operations and manpower according to a detailed plan”.

- During processing, the raw material undergoes changes to allow it to become a part of a product(s).

- Once processed, it should have worth in the market or a value.


- Therefore, it encompasses:- The design of the product.- The selection of raw materials.- The sequence of processes through which the product will be manufactured.

- Word production is often interchangeably with word manufacturing.


Manufacturing can be defined two ways:1) Technology – manufacturing is the application of physical and chemical processes to alter

the geometry, properties, and/or appearance of a given starting material to make parts or products. Manufacturing also includes the assembly of multiple parts to make products.

The processes to accomplish manufacturing involve a combination of machinery, tools, power, and manual labor.


ManufacturingProcess

Raw materialsProduct

Profit

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Too

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Po

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2) As an economic process.

ManufacturingProcess

Valueadded

Startingmaterial

Material inprocessing

Processedmaterial


Manufacturing is the transformation of materials into items of greater value by means one or more processing involve. Therefore, manufacturing is “added value” to the material.

- “Added value” – by changing the material’s shape or properties or by combining it with other materials that have been similarly altered.



MANUFACTURING

PURCHASINGMACHINERY & TOOLING

PROCESS PLANNING

MATERIALS

PRODUCT DESIGN

PRODUCTION CONTROL

SUPPORT SERVICES

SHIPPING

CUSTOMER SERVICE

MARKETING

SALES



Manufacturing activities must be responsive to several demands and trends:

A product must fully meet design requirements and specifications.

Manufactured environmental friendly and economical method.

Quality is built in each manufacturing stage.

Production methods must be flexible to respond to changing market demands, types of products, production rates and delivery time required.

New development in technology and managerial activities must constantly evaluated.

Manufacturing activities can be modeled to study the effect of factors on product quality and cost.

Organization must strive for higher quality and productivity.



MANUFACTURING INDUSTRIES

PRIMARY INDUSTRY

SECONDARY INDUSTRY

TERTIARY INDUSTRY

Industries can be classified as:


TYPES OF INDUSTRIES1) Primary industry

- Those that cultivate and exploit natural resources; eg: agriculture, mining.

2) Secondary industry- Take the outputs of the primary industries and convert them into consumer and capital goods.

3) Tertiary industry

- Constitute with service sector of the economy.




PRIMARY INDUSTRY

• Agriculture• Forestry• Fishing• Livestock• Quarries• Mining• Petroleum

SECONDARY INDUSTRY

• Aerospace• Automotive• Building

materials• Chemicals• Computers• Consumer

appliances• Food processing• Glass, ceramic• Pharmaceuticals• Plastics

(shaping)• Textiles• Tire and rubber• Wood and

furniture

TERTIARY INDUSTRY

• Banking• Communications• Education• Entertainment• Financial

services• Health and

medical• Government• Hotel• Insurance• Restaurant• Retail trade• Tourism• Transportation• Real estate



1) Project – 1 to 10 units.2) Job shop – 10 to 100 units.

3) Batch – 100 to 10,000 units.4) Mass – Above 10,000 units.

Production quantity: number of unit produced annually of a particular product type.

Product variety: different product designs or types that are produced in the plant.

[Low production]

[Medium production]

[High production]



Low

Medium

High

Prod

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Product quantity



Project

Job shop

Batch

Mass

Product variety

Prod

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1 to 10 units

10 to 100 units

100 to 10,000 units

Above 10,000 units



TYPE OF MANUFACTURING OPERATIONS

1) PROJECT

- Product position – remains stationary during the manufacturing process – size,weight, location of the product.

- Materials, people, machinery are brought to the product or product site.

- Example: bridge, building construction, aircraft, ships, locomotive.

- Based on customer specifications.



2) JOB SHOP PRODUCTION

- Low volume and production quantities called lot sizes with high product variety.

- Satisfies a market for nonstandard or unique product.

- Layout – different machines with similar functional or processing capabilities are grouped together as department.

- Require high skill levels labor – to operate a variety of equipments.

- Example: space vehicles, reactor vessels, turbines, aircraft components.- A short duration activities to provide custom goods.



3) BATCH PRODUCTION- Batch production produce or process any product in groups which is called “batches”.

- Can produce a variety of products – opposed to a continuous production process, or a one time production.

- Example: Similar standard items made periodically in batches: bakery, paint, hand tools.- Same facilities used to manufacture all the different items.

- Useful for industries that makes seasonal items/products for which it is difficult to forecast the demand.

- Layout of machine – functional layout (based on its function to be performed – from section to another section).



Advantages of batch production

- Reduce initial capital outlay – due to a single production line can be used to several products – machines can be used more effectively, materials can be bought in bulk, workers can specialize in that task.

Disadvantages of batch production- Requires very careful production planning & control – next batches; when, types.

- When switching to another batches – takes time (“down time”) – can cause loss of output (low yield).

- Resulted “WIP” or create inventory/stock – increases costs such as inventory cost, cost because of damage to stock.



The example production line (shown below) is that of an engineering company, manufacturing small steel products such as hinges and locks. They manufacture batches of five hundred at a time. The workers are unskilled and semi skilled. As each task is completed the item being manufactured is passed down the production line to the next worker, until it is complete.



4) MASS PRODUCTION- Also known as flow production, repetitive flow production, series production.

- Machinery (eg: robots, machine press) that is needed to set up the mass production line is so expensive.

- Involved fewer labor cost and a faster rate of production.

- Producing goods in large quantities at low cost per unit and produce in a short period of time.

- Plant and equipments are arranged in a flow line layout.

- Operation is done base on specific product and thus make the production control easily.

- Work piece is transfer automatically from one machine to another.

- Example: light bulbs, refrigerator, tv.



Manufacturing Approaches

Lean Production and Agile Manufacturing

CONCURRENT ENGINEERING

JUST IN TIME (JIT)

KANBAN SYSTEM



Benefits of Lean Manufacturing

- Overhead operating costs reduces by 30%.- Sales ($) per employee 10 times higher.- Profits 4 times.- Lead time cut by 50% to 90%.- Process queues cut by 70%.

Lean Production- A systematic approach to identifying and eliminating waste in manufacturing process through continuous improvement by following the product at the demand of the customer.

- Lean is about doing more with “less” i.e. less time, inventory, space, people, money; to minimize the cost.

- It is all about “speed” and getting it right at the first time.

00407

Add the relationship with JITIntroduced by toyota (history)

- Waiting time (waiting for the next production steps).- People’s talents, & motivations.- Motion (people or equipment moving or walking).

- Transportation.



PRINCIPLE OF LEAN MANUFACTURING- Voice of the customer.- Continuous improvement.- Recognize & eliminating waste of:

- Over production (production ahead of demand).- Inventory (all components, work-in progress (WIP) and finished product not being processed).- Defects (Non-zero defect rates – the effort involved in inspecting for & fixing defects).



AGILE MANUFACTURING

- Agile manufacturing is a term applied to an organization that has created the

processes, tools, and training to enable it to response quickly (flexible) to

customer needs and market changes while still controlling costs and quality.

-Flexibility – people, equipment, computer hardware and software,

communication

- The implementation of the principles of lean production on a broad scale.

Concurrent engineering (CE) is a philosophy that promotes interactive design and manufacturing efforts to develop product and process simultaneously, thus optimizing the use of company resources and reducing time to market cycles. It has four general phases which are:

Technology and concept development. Product and process development and prototype validation Process validation and product confirmation. Production and continuous improvement.

CONCURRENT ENGINEERING



- It tends to simplify and break the whole system into small, autonomous units.



JUST IN TIME (JIT)-Raw materials, parts & components are delivered to the manufacturer just in time to be used,- parts & components are produced JIT to be made into subassemblies & assemblies, -and products are finished JIT to be delivered to the customer.

- JIT is also known as “pull system” in contrast to traditional “push system”.



Benefit s/Advantages of JIT- Low inventory – carrying cost.

- Fast detection of defects in the production or the delivery of supplies and, hence,low scrap loss.

- Reduced inspection and reworking of parts.

- High quality products made at low cost.

- Reduction of :

60% to 80% in inventory. Up to 90% in rejection rates. 90% in lead times. 50% in scrap & rework.

20% to 40% in product cost. Benefit s/Advantages of JIT (cont’)

Increases:

- 30% to 50% in labor productivity.

KANBAN SYSTEM (Japanese)- Integrated with the implementation of JIT concept.

- Kanban – means “visible record”; it is a system of notification from one process to the other in a manufacturing system.- Originally consisted of two types of cards:i) Production card: authorizes the production of one container or cart of identical, specified

parts at a workstation.

ii) Conveyance/move card: authorizes the transfer of one container or cart of parts from that particular w/station to the w/station where the parts will be used.


The cards contain information on:

i) Type of parts.

ii) Location where issued.

iii) Part number.

iv) Number of items in container.@jurie 2009 – Lecture 1

Lecture 01 2010

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Transcript of Lecture 01 2010